Product Support Bulletin

Transcription

1 MODEL: SUBJECT: CONVENTIONAL, W/ C7 CAT ENGINE WEBASTO TSL-17 HEATER Body DATE: APRIL 13, 2004 INDEX: 6 PAGE: 1 OF 16 Before you start this procedure, perform Freightliner Service Bulletin #20-7 first. A Webasto heater has been made available to provide increased water (or coolant) temperatures for the bus heating system. This heater is currently available for C7 Cat engines. Follow the procedure below to install. 1. Heater Sub-assembly to Base Plate: 1.1. Mount heater unit to Heater Bracket, part # , using three hex head screws included in Webasto package. Figure 1. The screws will tap into the holes on the heater. Make sure that the pump side of the unit is mounted away from the open slots on the base plate. The screws take a 10mm socket. Figure Take the air intake tube (metal shielded with cardboard tube) and pull the cardboard tube out of the metal shield 1". Trim 3/4" off the cardboard tube and push it back inside the metal shield. Figure 3. Install the heater air intake tube to the heater using the clamp provided in the kit. Figure 4. Note: Use the appropriate Clamp to match Hose type. Hex Head Screws Figure 1 Trim 3/4" off Cardboard Liner Pump Side Figure 2 Clamp Slot Product Support Bulletin Figure 3 Figure 4

2 PAGE: 2 of 16 INDEX: Secure the tube to the Heater Bracket using one of the non-insulated P-clamps provided with the Webasto Kit and one Tapping Screw, part # The end of the tube should extend 1" past the edge of the plate. Make sure that the plastic fitting is still installed on the free end of the air intake, as the crossbar on this piece is to keep debris from being sucked into the heater. Figure 5. Clamp Plastic Fitting Figure 5 2. Mounting the Heater and Heater Bracket to the Vehicle Frame: 2.1. Loosen the two bolts supporting the fuel line bracket on the left frame rail of the vehicle, just behind the transmission. Figure Install the Heater Assembly by sliding the two slots on the side of the bracket onto these bolts and re-tighten Fasten the Heater Bracket using the 1/2" Flange Head Bolts, # , Flatwashers, # , and Locknuts, # , through two of the four holes provided on the opposite side of the Heater Bracket. Figure If there is a Button Head Tie Wrap, # , securing lines through one of the four mounting holes, remove it, install the heater, and re-secure the lines using the Button Head Tie Wrap included with this kit. Button Head Tie- Wraps 2 Existing Bolts New Bolts Figure 6 Figure 7 3. Fuel Pickup Installation: 3.1. Remove the fuel sender access cover from inside the bus. Figures 8a & 8b Mark the orientation of the sender (before removing from tank; the bolt pattern is not symmetric), and remove the fuel sender from the fuel tank.

3 PAGE: 3 of 16 INDEX: Cut the new Fuel Pickup Tube, # , to length. The tube should measure 12.5" long for side-mount tanks, and 14.75" for BTR-tanks, measured from the bottom of the mounting flange to the end of the pickup tube. Cut the end at a 45 o angle and carefully deburr the cut. Figure Drill the holes in the new gasket for the fuel sender out to 3/16", to allow easy passage of the mounting screws. Make sure there is a gasket positioned between the tank and the new pickup mounting flange, and one between the new pickup and the sender. Make sure that the gaskets are oriented with the hole-pattern on the sender Insert the sender through the new fuel pickup tube for the Webasto heater. It will be necessary to remove the float off the fuel sender arm. Be sure to re-install it in the same orientation to the sender Verify the orientation of the pickup with the fuel sender before inserting the pair into the tank. See Figures 8a & 8b Make sure that the fuel pickup tube does not contact any of the fuel sender electrical components, and that the sender arm can still move freely. Some slight bending of the tube may be required Carefully insert the fuel pickup and sender into the tank. Partially insert the fuel pickup tube, then maneuver the float through the hole in the tank. After both components are in the tank, carefully orient them as originally planned. Do not force the components into position, as they may bend or interfere with correct fuel level readings. Make sure that the gaskets are correctly aligned Install the five new Machine Screws, # , for the unit, and securely tighten. Access Cover Removed New Fuel Line Figure 8a Side Mount Tank Note orientation! New Fuel Line Figure 9 Figure 8b BTR Mount Tank Note orientation!

4 PAGE: 4 of 16 INDEX: 6 4. Fuel Pump and Filter Installation: 4.1. Locate on the crossmember nearest the fuel tank. Mount the pump using existing holes in the crossmember. The mounting location can be up to 6 feet from the pickup tube. On longer buses, it is better to have the pump mounted as close to 6 feet from the tank as possible. Do not mount the fuel pump above the top of the frame rails The fuel pump mounts using the P-clamp found inside the fuel pump bag. Secure the pump using the 5/16 Hex Flange Head Bolt, # , Nut, # , and Flatwashers, # Do not mount the pump to any body structures, only to the vehicle frame. Figures 10a & 10b The fuel flow direction is from the tank to the filter, then into the pump. Pump outlet goes to the Webasto heater Make sure that the electrical connector is exposed to allow easy hookup later in the installation process. Side Mount Tank Electrical Connector BTR Mount Tank Electrical Connector Filter Filter Pump Fuel Flow Pump Fuel Flow Right Side Frame Rail Right Side Frame Rail Figure 10a Figure 10b 5. Fuel Line Installation: 5.1. Be sure to protect all fuel lines with 3/8" Conduit, # , provided for this purpose Route the fuel line from the tank to the fuel pump mounting location. Do not run the line through any holes without shielding, either with a grommet or split loom. Do not stretch or kink the hose. Allow some slack to accommodate vibration There are two types of fuel line used for the heater: 1/8" rubber hose and 2mm plastic tubing If your kit has the 2mm plastic lines, there are short segments of rubber hose used for making the connections. Figure X1. These connections must be carefully made to insure no air bubbles are trapped in the system. Refer to Figure X2 for details on connections 5.5 Secure both ends of the hose with the clamps provided in the Webasto kit. 5.6 Re-install the fuel sender access plates in the bus floor Fuel Pump shows the rubber fuel hose. Plastic Fuel line with rubber hose coupler. Figure X1 Figure X2

5 PAGE: 5 of 16 INDEX: 6 6. Engine Plumbing Connection: 6.1. Open hood. Cut off all heater valves Locate the heater return line from the body heaters. The hose should have a T, with the side leg going into shutoff valve. On some units, this hose is located on the left side of the engine near the surge tank. Plastic T-Fitting, # , will be installed in this line. Figures 11 & Assemble the Plastic 3/4" Hose Barb, # and the Plastic T-Fitting with the threaded side port. Use sealant on the threads Plan the orientation of the fitting and cut the 1" hose in the single supply line near the shutoff valve. Be sure to allow enough room for the barbs to fully engage in the hose without interfering with other connectors Install the Plastic T and secure it to the hoses with the two 1" Heater Hose Clamps, # Make sure that the side of the T is oriented to allow smooth routing of the new coolant hose for the Webasto heater Install Barb Fitting, # into the thermostat housing, see Figure 13. Connect the Webasto return line to this fitting using heater hose Clamp, # Old style Heater Plumbing Heater Supply Add Plastic T- Fitting here. Figure 11 Figure 12 Heater Return Heater Hose Clamp Barb Fitting Figure 13

6 PAGE: 6 of 16 INDEX: 6 7. Hose Routing: 7.1. Shield all 3/4" Heater Hoses, # , with the 1.25" Conduit, # , provided The hose running to the upper engine connection installed in step 6.2 connects to the black plastic water pump located on the side of the heater. Figure The hose running from the outlet of the Webasto heater connects to the engine body heater return T (plastic T installed in 6.5) Route the hoses from the heater, underneath the outrigger and over the fender, up into the engine compartment, and along the existing heater hose runs Use the 1 1/2" Double Hose P-clamps, # provided to secure the hoses and shielding to the fender. The two 3/8" Flange Nuts, # , provided can be used to mount the P-clamps over the existing fender nuts. Figure 14 & Secure the hoses along their routing using the 24" Tie Wraps, # , provided Secure both ends of the hoses using the 5/8" Heater Hose Clamps, # , provided. Double Heater Return T Double Figure 14 From Upper Engine Connection Figure Rewire Procedure: The TSL-17 heater is wired from the factory to cut back to a partial burn state at 142 o F. This procedure will increase that temperature to 161 o F. This will help build more heat in the engine during the preheat phase and help the heater to maintain that heat more effectively Find the heater unit (mounted on the left frame rail ahead of battery box area.) Note: The connectors must be at room temperature before performing this procedure to help prevent breaking the plastic connector parts Locate the wiring harness plugs on the top of the heater. It may be necessary to remove the splash shield to see the connectors. You will be working with the 6 pin connector. This connector has 3 wires in it. Unplug the connector from the heater and move to an accessible location. Remove the tape from the wire loom and peel the loom away from the wires. Push the two locking pins on the outer shroud of the connector towards the outside of the connector and slide the outer shroud of the connector down over the wires. Figure Locate the green lock tab and push the top ear down and move the lock out of the connector by sliding it to the left. This will free up the terminal ends. Figure 17 & You will be changing the position of the black wire in this plug. The black wire is originally in pin #3 or to the left of the yellow wire if you hold the connector with the black and yellow wires in the top row as you look at them from the wire end. To remove the black wire from the connector, you will have to push down on the little locking tab in the middle of the silver terminal end and pull the

7 PAGE: 7 of 16 INDEX: 6 Figure 16 Figure 17 Figure 18 Figure 19 wore out of the connector. Then remove the blue seal from the #1 cavity and move it to the #3 cavity to fill the hole just created by removing the wire. Now, insert the black wire into the #1 cavity making sure to orient the connector properly. Figure 19, 20, 21, & Reinstall the green lock tab removed in step 15.3., ensuring that it clicks back into place. Then reinstall and tape the wire loom back on the harness and reinstall the plugs into the heater and install any shields removed to gain access to the plugs. Test fire the heater to be sure that it runs properly. This completes the change and the heater should now run at full fuel up to 161 o F. Figure Wiring Harness Installation: Heater Unit Plug the two connectors on the harness provided by Webasto into the top of the unit. Figures 23 & The large plastic enclosure on the end of one lead encloses the two fuses for the unit. Secure this to the air intake tube using two wire ties. Be sure that the fuse enclosure is located after

8 PAGE: 8 of 16 INDEX: 6 Figure 20 Figure 21 Harness Connectors Grounds to Chassis Ground Stud Figure 22 Figure 23 Fuse Enclosure the end of the air intake pipe and positioned so that they can be checked without removing the dust shield (not installed yet). Figure There is a lead with brown wires running into two large ring terminals. These are main ground leads. Attach these to the frame rail ground for the main battery cables. This should be on the outside of the left frame rail about 2 feet behind the heater installation. Figure Fuel Pump The long lead with the blue and brown leads runs to the fuel pump Route the fuel pump lead and the fuel line from the fuel pump to the heater, following the routing of the main vehicle fuel lines as much as possible. Be sure to protect all fuel lines with 3/8" Conduit (split loom), provided for this purpose. Do not run the heater fuel lines over the top of the frame rails, either go through existing hole (preferred) or underneath the frame when necessary. Figures 25 & Support fuel line and wiring harness every 12" with tie wraps.

9 PAGE: 9 of 16 INDEX: 6 Secure Fuse Enclosure Lead to Air Intake Hose Harness Connectors Figure 24 Figure 25 Brown Grounding Lead (Shown in orange for clarity.) Fuel Pump Lead & Fuel Line Figure 26 Figure Secure both ends of the fuel line with the clamps provided in the Webasto kit. Refer to section Insert the white seals provided onto the wires and strip the ends of the wires Crimp on the terminals for the connector (provided in the fuel pump package in the Webasto Kit). These are AMP Junior Power Timer terminals. The connectors take die assembly for the Pro-Crimper II. Be sure the seals are crimped on as shown in Figure Insert the terminals into the connector housing. The brown lead is installed in position 1 and the blue lead into position 2. Push the seals into the cavities at the back of the connector. Figure Depress the locking wire and push the completed connector onto the fuel pump. The wire should snap up and secure the connector into position. To release the connector, depress the locking wire and pull back on the wire. See Figure 30a & 30b.

10 PAGE: 10 of 16 INDEX: 6 Seals located under crimp Figure 28 Figure 29 Wire up & locked. Wire down & not locked. Figure 30a Figure 30b Caution: Prior to making any connections to the vehicle electrical system, be sure to disconnect the battery. Failure to do this could result in damage to yourself or the vehicle Cab Wiring Leads Route the two remaining harness branches above the body outrigger and then along the same route as the new coolant lines up toward the firewall. Secure the harness branches to the bus floor with one 3/4" Cushion Clamp, # , and Tapping Screw, # Figure 27. Secure them to the hoses with wire ties. Route these two wiring harnesses into the cab through the 3/4" grommet on the firewall to the left of the engine. There are other lines running through this grommet already, but these two new leads will fit (snugly). Do not remove the split loom from the wires where they run through the grommet. Figure Route the two harness branches over the driver's left side console Locate the harness branch with two wires (red and brown). Crimp a ring terminal onto the brown lead and connect it to the switch cabinet ground stub.

11 PAGE: 11 of 16 INDEX: Crimp Ring Terminal, # , onto the brown lead and connect it to the switch cabinet ground stud. Figure Install a 25 amp fuse, part # Locate the other harness branch (with the.25" female push-on terminals crimped on the ends) Connect the black wire push-ons to terminals 3 and 6 of the new Heater Control Switch, # Figure Connect one of the brown leads to terminal Tape off the two red lead spade terminals; they are not used for standard switch controlled installations. These are hot leads used for timer installation and must be covered Attach the ring terminal to the ignition side of the body board #1 located in the switch cabinet. Figure Install the new Heater Control Switch in the console in an available location. Note: Use the appropriate Clamp to match Hose type. Ground Ignition Battery NOTE: Torque nuts 65 in. lbs. Board #1 Grommet Figure 31 Figure 32 Bottom View Terminal Arrangement Figure Dust Shield: 9.1. Install a 1/2", # , around the fuel line with the flat side facing away from the frame rail. It will be secured by the lower forward dust shield mounting screws. Figure 34a & 34b Install the Dust Shield, # , to the frame using the four #12 Tapping Screws, # , provided in the kit. Figure 35.

12 PAGE: 12 of 16 INDEX: 6 Dust Shield Support behind Dust Shield Figure 34a Figure 34b Dust Shield Figure Exhaust Piping: Install the exhaust pipe to the heater using the steel clamp provided Route the exhaust pipe to the side of the bus along the battery box. Secure in place using the steel (non-padded) s, provided in kit. To make standoff for the rear support (if needed), remove the plastic insulation from one, # , flatten it, and secure it to the steel for the pipe with the 1/4" Cap Screw, # , Kep Locknut, # , and Flatwasher, # , provided. Figure 36a & 36b Clamp the end of the exhaust pipe to the edge of the bus clamping it behind the finishing cap on the end of the hose, and securing it near the corner of the battery box. Bend the very end of the pipe to point it toward the rear of the bus.

13 Draft PAGE: 13 of 16 INDEX: 6 Steel Steel Steel s Figure 36a Figure 36b 11. Wrap-up: Refill coolant system Check to make sure that all parts loosened or removed are tightened and replaced Make sure that heater valves are open Reconnect the vehicle batteries Run engine to purge air Verify that there are no leaks and that all lines are secured Make sure enough fuel is in the tank to submerge the end of the fuel pickup for the heater, 1/4 tank should be sufficient. If the gauge reads empty and there is fuel in the tank, be sure that the sender was reconnected. 12. Priming the Heater Fuel System: Make sure that the heater return valve is in the open position. This is the valve in the line we plumbed into with a plastic T. Never attempt to run the heater with this valve closed, as the coolant will not be able to circulate Turn the key into the run position. The heater is wired to run when the key is on or in the accessory position. This will prevent drivers from accidentally leaving the unit on all night Turn Webasto heater switch to the ON position. This starts the unit's automatic cycle. The combustion air blower will be moving air through the unit, and the coolant pump will be turning. The fan speed will change, and a clicking noise will be heard. The clicking is the fuel pump cycling After a few minutes the unit will probably shut off because it has not received fuel. Turn the switch off and back on to reset the unit. It may take several cycles to prime the fuel system. When the unit finally starts, it will operate fully automatically until turned off. IMPORTANT NOTE: After trying three times and the burner does not start, disconnect the battery supply to the heater. This will reset the memory When the heater is turned off, its air blower will continue to run to cool the unit down. It will shut off in a couple of minutes without any further inputs. 13. Normal Operation of Unit: Make sure the heater return valve is in the open position. This is the valve in the line that was plumbed into with a plastic T. Never attempt to run the heater with this valve closed, as the

14 PAGE: 14 of 16 INDEX: 6 coolant will not be able to circulate Installation of a winterfront is recommended to reduce heat loss and improve cabin heater performance Turn the key into the run position. The heater is wired to run when the key is ON or in the Accessory position. This will prevent drivers from accidentally leaving the unit on all night Turn Webasto heater switch to the ON position. This starts the unit's automatic cycle The unit will run as long as the switch is in the ON position with the ignition in the ON or Accessory position. It will attempt to maintain a coolant temperature between 133 and 161 by cycling the burner as needed. The dash gauge may read lower than this due to differences in where the temperature is measured The unit will preheat an engine in about 1/2-1 hour depending on ambient conditions. Colder ambients will increase preheat time. Preheating (even for shorter periods) with the engine off will make cold weather starting easier Leaving the unit on while the bus is running will warm the passenger compartment quicker, and bring the engine temperature up into a better operating range. The automatic controls on the unit will not allow it to overheat the engine When the heater is turned off with the switch or the key is turned off, its air blower will continue to run to cool the unit down. It will shut off in a couple of minutes without any further inputs. Consult Webasto TSL-17 Installation and Service Manual for Maintenance guidelines and requirements. 14. Additional Pre-trip Warm Up Suggestions: Start engine and set advanced idle speed to 1000 rpm's. Turn the switch on for the Webasto TSl- 17 heater. Waite 2-3 minutes and check the Webasto heater exhaust to be sure it is running For units equipped with right side stepwell heaters, turn the blowers on high Leave all left side heaters in the off position and make sure the thermostat control is off. This will prevent the flow of water to the left side heaters, reducing the amount of water the engine must heat before getting started Upon starting your trip, turn the left side heaters on and booster pump, if unit is equipped with one If your unit does not have a right side stepwell heater, the left side driver's heater should be turned on low fan during warmup Upon starting your trip the underseat heaters should be turned on. 15. Extensive cold weather testing has shown that 2004 EPA diesel engines currently offered in the Thomas product line are more efficient and do not produce as much heat at idle or under light loads. The Webasto TSL-17 heater has been installed as a supplemental heat source on many FS-65 buses, and will provide additional heat to the system. Awareness of the way the heater is designed to operate will help you understand and identify problems with the unit The heater is not designed to get the engine up to full operating temperature with the cabin heaters running. The cabin heaters can remove a huge amount of heat from the engine. (See pretrip warm up suggestions.) The heater is a self-contained automated system. When it is turned on, either with the manual switch or a timer, it has a programmed routine that it runs through. This includes a glow plug and warmup, fuel pump cycling, and a cool down phase If you suspect the heater is not functioning, check if the heater is moving air. If the blower is not running (no air coming thought the exhaust pipe) start troubleshooting the system. Also check if the fuel pump is working. The fuel pump is heard as a clicking sound from the vicinity of the fuel tank when the unit is operating The heater is thermostatically controlled and will automatically shutoff once the engine temperature reaches 165 o F. The coolant circulation pump will continue to run and monitor the system for additional heating needs.

15 PAGE: 15 of 16 INDEX: For manually switched units, the key must be in the on or accessory position for the heater to run and it was set up this way to prevent accidentally leaving the unit on over weekends. After the unit is switched off, the heater will continue to run in a "cool down" cycle that minimizes smoking on startup If equipped with optional timer, it is connected to battery power to allow the heater to run per its program without the key being in the on or accessory position, but has a limited run duration, preventing it from staying on over an entire weekend. When the timer run is completed, or after 2 hours, the heater will run through a cool down and shut off The fuel pickup tube is mounted higher than the one for the engine, causing the heater to shut down prior to the engine running out of fuel. The heater may not run as desired if the fuel level falls below ¼ tank If the unit runs out of fuel, it will self re-prime, but this may take several (up to 6) operating cycles to prime the fuel system. The fuel line is translucent so you can see if there is fuel in the line or not The heater has automatic flame sensing. If it is trying to run and the unit does not sense flame, it will automatically shut down. This is an important safety feature. Switch the unit off and back on to re-start the system cycle and continue priming the fuel lines. If you have a timer and the unit locks itself out from a fault during re-priming, follow the manufacturers instructions to clear the fault and continue priming the system. MATERIALS REQUIRED: KIT # CONSISTING OF THE FOLLOWING PARTS. PART # QTY. DESCRIPTION Screw - Cap, Hex,1/4-20 x 1" Nut - Kep, Hex Lock, 1/ Washer - Flat, 1/4" Cushion Clamp () Tapping Screw, #12 x Cushion Clamp () Cushion Clamp (Double ) 1 1/2" ' Conduit - Convolute.350" ' Conduit - Convolute 1.25" Bolt - Hex, Flange, 5/16-18 x 1" Nut, Flange - 5/ Washer - Flat, 5/ Nut, Flange - 3/8" Tie Wrap, 24" Machine Screw #10-32 x 1" Clamp - Heater Hose, 1" Clamp - Heater Hose, 5/8" Bolt - Flange, 1/2-13 x 1 1/2" Nut - Lock, 1/2-13 Hex Washer - Flat, 1/2" ' Hose, Coolant, 3/4" Fuel Pickup Tube Button Head Tie Wrap, 15" Switch - Heater Control Nipple, Hex Reducer, 1/2 NPT to 3/8 (Adapter)* Fitting - Tee, 1/2", Brass* Fitting, Hose, 1/2 P - 3/8 H* Adapter - Brass Straight, Male M20x1.5 to Female 3/8" NPT

16 PAGE: 16 of 16 INDEX: Barb, 3/4 Hose, 1/2" NPT Tee, Plastic, 1" Hose, 3/4 NPT Barb, Plastic 3/4 Hose, 3/4 NPT Heater Bracket Weldment, Frame Mount Dust Shield Heater Kit, Webasto TSL-17 1 Switch to Dash Lights Jumper (Fabricate on sight.) Fused Jumper Leads Wire Tie, 8" Fuse, 25 Amp, ATO Type Fuse, 3 Amp, ATO Type Terminal, Ring, #10 Screw Terminal - Male Disconnect, WARRANTY STATUS: SIX MONTHS FROM THE DATE OF THIS BULLETIN. ELECTRONIC WARRANTY CODE: 6523 FLAT RATE: 66-32, Time Allowance hrs.